Ultra precision machining technologies are being developed along with the requirement for more precision products in modern industrial fields. The products are being required not only for high precision but also for high machining efficiency. Magneto-electrolytic-abrasive-polishing (MEAP) is one of the effective finishing process which combines three kind of machining processes and energy together, through the large amount of experiments it has been proved a high precision and high efficiency machining method especially to difficult-to-cut materials. Rightly, the nonwoven abrasive pads as a new type important polishing tool which can be used in MEAP system is being payed more attention. The nonwoven abrasive pads are used in MEAP system then the machining process can achieve high efficiency and obtain fine workpiece surface thanks to nonwoven abrasive pads' three-dimensional and elastic structure. In this research, WA ($Al_2O_3$), GC (SiC) and diamond nonwoven abrasive pads are developed, their basic polishing characteristics are proved by applied on difficult-to-cut material Cr-coated roller.
Recently, large amount of copper and aluminium roller are being used in modern printing industry, the demand for precision and efficient manufacturing process of these difficult-to-cut materials is becoming more emergency.
In this study, the new type polishing materials of WA, GC and diamond nonwoven abrasive pads are developed. Through the basic experiments, the machining characteristics and basic machining conditions of magneto- electrolytic polishing process about Cu and Al2024 are analyzed. Then, the machining process of magneto-electrolytic-abrasive polishing by using the newly developed nonwoven abrasive pads on copper and aluminium roller are carried out. The optimal machining conditions are found by using "Taguchi approach to parameter design". When the difficult-to-cut materials copper and aluminium roller are machined on MEAP system by using the optimal machining conditions, mirror-like surface are obtained in a relatively short machining time. In conclusion, magneto-electrolytic- abrasive polishing method by using the newly developed nonwoven abrasive pads can achieve high precision and high efficiency finishing result concerning to the difficult-to-cut materials, high quality mirror-like workpiece surface can be realized.
